ENGINE UNIT(w/o Glow Plug Controller) DISASSEMBLY

PROCEDURE

  1. REMOVE WATER TEMPERATURE SENSOR

    1. A205753

      Using a 19 mm deep socket wrench, remove the water temperature sensor and gasket.

  2. REMOVE OUTLET WATER SUB-ASSEMBLY

    1. A205754

      Remove the 2 bolts, 2 nuts and outlet water sub-assembly.

    2. Remove the water outlet gasket from the cylinder head sub-assembly.

  3. REMOVE WATER INLET

    1. A246056

      Remove the 3 bolts and water inlet.

    2. Remove the No. 1 water inlet housing gasket from the water inlet.

  4. REMOVE OIL PRESSURE SENDER GAGE ASSEMBLY

    1. A200100

      Using a 27 mm deep socket wrench, remove the oil pressure sender gage assembly.

  5. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    1. Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.

    2. Using a screwdriver with its tip wrapped with protective tape, remove the oil filler cap gasket.

  6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A198335

      Remove the 12 bolts and cylinder head cover sub-assembly.

    2. Remove the cylinder head cover gasket from the cylinder head cover sub-assembly.

  7. REMOVE ENGINE MOUNTING BRACKET RH

    1. A200032

      Remove the 4 bolts and engine mounting bracket RH.

  8. REMOVE NO. 2 TIMING CHAIN COVER

    1. A246055

      Remove the bolt, manifold temperature sensor bracket and No. 2 timing chain cover.

  9. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY

    1. A298150

      Remove the bolt and oil pressure switching valve assembly.

  10. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

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  11. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    1. A256905

      Remove the 20 bolts and the 2 nuts.

    2. A202763C03

      *a

      Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the timing chain cover sub-assembly by prying between the cylinder head sub-assembly and cylinder block sub-assembly.

      Note:

      Do not damage the contact surfaces of the timing chain cover sub-assembly, cylinder head sub-assembly or cylinder block sub-assembly.

    3. A246051

      Remove the oil pump gasket.

  12. REMOVE TIMING CHAIN COVER OIL SEAL

    1. A256906C02

      *a

      Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the timing chain cover oil seal.

  13. REMOVE OIL CHECK VALVE SUB-ASSEMBLY

    1. A246050

      Using a 6 mm hexagon socket wrench, remove the bolt and oil check valve sub-assembly from the timing chain cover sub-assembly.

  14. REMOVE INLET WATER HOUSING

    1. A255685

      Remove the 3 bolts and inlet water housing from the timing chain cover sub-assembly.

    2. Remove the No. 2 water inlet housing gasket from the inlet water housing.

  15. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Note:

    Do not rotate the crankshaft with the No. 1 chain tensioner assembly removed.

    1. A286864C03

      *a

      Push

      *b

      Plunger

      *c

      Groove

      *d

      Hole

      Push in the plunger until the groove is aligned with the hole, and then insert a 1.1 mm (0.043 in.) diameter bar.

    2. A198527

      Remove the 2 bolts and the No. 1 chain tensioner assembly.

  16. REMOVE CHAIN TENSIONER SLIPPER

    1. A198525

      Remove the chain tensioner slipper.

  17. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    1. A296125

      Remove the 2 bolts and the No. 1 chain vibration damper.

  18. REMOVE CHAIN SUB-ASSEMBLY

    1. A198523E01

      w/o Stop And Start System:

      1. Using SST, hold the camshaft timing sprocket.

        09960-10010

        09962-01000

        09963-01000

      2. Remove the 3 bolts and the camshaft timing sprocket.

      3. A194558

        Remove the camshaft timing sprocket, crankshaft timing sprocket and chain sub-assembly together.

    2. w/ Stop And Start System:

      1. A297909

        Remove the 3 bolts while holding the hexagonal portion of the camshaft, and then remove the camshaft timing sprocket and sensor plate.

      2. A194558

        Remove the camshaft timing sprocket, crankshaft timing sprocket and chain sub-assembly together.

  19. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    1. A198517

      Remove the chain tensioner plate with the chain damper spring from the pin.

    2. A198516

      Insert a 4 mm (0.157 in.) diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then remove the nut.

    3. A198515

      Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain sub-assembly together.

  20. REMOVE CHAIN DAMPER SPRING

    1. A198518

      Remove the chain damper spring from the chain tensioner plate.

  21. REMOVE CAMSHAFT

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  22. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

    1. G035812

      Remove the 8 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

  23. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    1. A198510E01

      Using several steps, loosen the 10 cylinder head set bolts in the order shown in the illustration, and then remove the 10 cylinder head set bolts and 10 plate washers.

      Note:

      • When removing the cylinder head set bolts, do not drop the plate washers into the engine.

      • Removing the cylinder head set bolts in the wrong order may cause damage to the cylinder head sub-assembly.

    2. Remove the cylinder head sub-assembly.

  24. REMOVE CYLINDER HEAD GASKET

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  25. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    1. A198502

      Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.

  26. REMOVE OIL FILTER ELEMENT

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  27. REMOVE OIL COOLER ASSEMBLY

    1. A200028

      Remove the 2 bolts, 2 nuts and oil cooler assembly.

    2. A200029

      Remove the 2 O-rings and gasket from the oil filter bracket sub-assembly.

  28. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

    1. A200030

      Remove the 2 bolts and oil filter bracket sub-assembly from the oil pan sub-assembly.

    2. A200031

      Remove the gasket from the oil pan sub-assembly.

  29. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    1. A200097

      Remove the oil pan drain plug and gasket.

    2. Remove the 10 bolts and 2 nuts.

    3. A286866C02

      *a

      Oil Pan Seal Cutter

      Insert blade of an oil pan seal cutter between the oil pan sub-assembly and No. 2 oil pan sub-assembly, and cut the applied seal packing.

      Note:

      Do not damage the oil pan sub-assembly or No. 2 oil pan sub-assembly.

    4. Remove the No. 2 oil pan sub-assembly.

  30. REMOVE ENGINE OIL LEVEL SENSOR

    1. A200044

      Remove the 5 bolts and the engine oil level sensor.

      Note:

      Do not deform the engine oil level sensor float or allow it to come in contact with other parts.

    2. Remove the gasket from the engine oil level sensor.

  31. REMOVE OIL PAN SUB-ASSEMBLY

    1. A200096

      Remove the 12 bolts.

    2. A286867C02

      *a

      Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the oil pan sub-assembly by prying between the cylinder block sub-assembly and oil pan sub-assembly as shown in the illustration.

      Note:

      Do not apply excessive force when prying between the cylinder block sub-assembly and oil pan sub-assembly.

  32. REMOVE ENGINE REAR OIL SEAL

    1. A198495

      Remove the engine rear oil seal.